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How to Deep Clean a Dan Wesson 44 Revolver

Image featuring a Dan Wesson 44 Magnum Deep Cleaning
Jump To:
  1. Full Step-by-Step Dan Wesson 44 Disassembly, Cleaning, and Reassembly Guide
  2. Jump Links
  3. Safety and bench setup
  4. Tools and supplies
  5. Step 1: Initial barrel inspection
  6. Step 2: Diagnose the barrel nut problem
  7. Step 3: Build the custom barrel tool
  8. Step 4: Remove barrel and shroud
  9. Step 5: Front sight removal
  10. Step 6: Grip removal
  11. Step 7: Capture the mainspring
  12. Step 8: Rear sight disassembly
  13. Step 9: Hammer removal
  14. Step 10: Trigger guard and trigger removal
  15. Step 11: Crane and cylinder disassembly
  16. Step 12: Frame internals removal
  17. Step 13: Ultrasonic cleaning
  18. Reassembly overview
  19. Step 14: Frame reassembly
  20. Step 15: Crane and cylinder reassembly
  21. Step 16: Trigger group reassembly
  22. Step 17: Hammer installation
  23. Step 18: Rear sight reassembly
  24. Step 19: Grip install
  25. Step 20: Barrel gap, shroud, and barrel nut
  26. Step 21: Final cleaning and range prep
  27. FAQ
  28. What is the correct Dan Wesson barrel-to-cylinder gap?
  29. What if the barrel nut is damaged or rounded?
  30. Do I have to use an ultrasonic cleaner?
  31. Could a cylinder drag line be from someone spinning the cylinder?
  32. What should I check after reassembly before live fire?
  33. Related deep cleaning guides

Full Step-by-Step Dan Wesson 44 Disassembly, Cleaning, and Reassembly Guide

This Dan Wesson 44 Magnum came from the same estate sale as the Glock 29 deep cleaning. It rode hard in Montana backcountry and it shows. The barrel nut alone tells you this revolver lived a life.

This guide is written like a bench manual. Not a transcript.

You can follow it with the video or use it standalone.

Safety and bench setup

Video: https://youtu.be/7hEL7NUBXSw?t=44

  • Verify unloaded
  • Remove all ammo from the area
  • Eye protection on
  • Parts tray ready
  • Good lighting, no clutter

Tools and supplies

Video: https://youtu.be/7hEL7NUBXSw?t=54

You’ll need:

  • Punches and roll pin punches
  • Hex and Allen bits
  • Feeler gauge (0.006 inch)
  • Dan Wesson barrel nut wrench
  • Bore cleaning cable or rod, brushes, patches
  • Ultrasonic cleaner (recommended)
  • Controlled heat source

Affiliate resources (listed once, like a normal manual):

Step 1: Initial barrel inspection

Video: https://youtu.be/7hEL7NUBXSw?t=73

Goal: confirm the barrel is worth your time.

  • Inspect the bore visually
  • Run a brush to loosen fouling
  • Patch until you can see the bore surface
  • Expect lead fouling on estate revolvers

Stop if you see cracks or deep pitting that looks structural.

Step 2: Diagnose the barrel nut problem

Video: https://youtu.be/7hEL7NUBXSw?t=118

Normal Dan Wesson barrel system:

  • Remove barrel nut
  • Slide shroud off
  • Unthread barrel

If the nut is damaged, rounded, or seized:

  • Shift focus to the barrel-to-frame threads
  • Work penetrating lubricant into the junction from the chamber side
  • Let it soak

Step 3: Build the custom barrel tool

Video: https://youtu.be/7hEL7NUBXSw?t=173

This tool lets you spin the barrel out from inside the shroud.

  • 3/8-16 x 9 inch bolt
  • Washer
  • Copper washer trimmed to fit
  • Electrical tape to protect bore
  • Double-nut the rear so nothing slips

Key detail: trim the copper washer so it spins with the barrel and does not bind the shroud.

Step 4: Remove barrel and shroud

Video: https://youtu.be/7hEL7NUBXSw?t=244

Prerequisite: Revolver unloaded. Barrel junction soaked as needed.

  1. Apply heat to the frame, not the barrel
  2. Use the internal tool to start the barrel moving
  3. Once it breaks free, run it out steadily
  4. If the shroud sticks, use light tapping to free it
  5. Remove shroud, then remove barrel

Inspect barrel threads and frame threads. Clean thread debris before reassembly.

Step 5: Front sight removal

Video: https://youtu.be/7hEL7NUBXSw?t=324

  • Use the 0.050 Allen bit
  • Loosen screw
  • Rock sight rearward and lift out
  • Inspect for rust underneath

Step 6: Grip removal

Video: https://youtu.be/7hEL7NUBXSw?t=361

  • Use the 5/32 bit
  • Remove grip screw
  • Slide grip off tang

Step 7: Capture the mainspring

Video: https://youtu.be/7hEL7NUBXSw?t=383

  • Use the 5/64 bit to remove the mainspring retaining screw
  • Cock the hammer
  • Thread the screw into the mainspring guide to capture the spring

Step 8: Rear sight disassembly

Video: https://youtu.be/7hEL7NUBXSw?t=414

  • Drive out the roll pin above the cylinder using a 1/16 roll pin punch
  • Hold the sight down since springs are underneath
  • Remove the flathead elevation screw
  • Remove springs
  • Remove the blade (0.050 bit). Tap lightly as needed

Step 9: Hammer removal

Video: https://youtu.be/7hEL7NUBXSw?t=508

  • Drive hammer pivot pin with a 9/64 brass punch
  • Hold trigger back
  • Rock hammer out

Then disassemble hammer:

  • Drive strut pivot pin with 1/16 punch
  • Remove strut, plunger, spring

Step 10: Trigger guard and trigger removal

Video: https://youtu.be/7hEL7NUBXSw?t=585

  • Depress trigger assembly latch using a 3/16 brass punch
  • Rock trigger guard forward and remove
  • Control the hand, connector, and small spring
  • Remove latch and spring (1/16 roll pin punch)
  • Drive trigger pivot pin (3/32 punch)
  • Remove trigger and trigger return spring and guide

Step 11: Crane and cylinder disassembly

Video: https://youtu.be/7hEL7NUBXSw?t=666

Prerequisite: Trigger guard removed.

  • Remove crane lock
  • Unscrew ejector rod
  • Remove extractor
  • Remove crane
  • Remove bolt plunger and spring
  • Separate cylinder from crane
  • Remove ejector rod bushing and spring
  • Remove crane latch retaining screw with 0.050 bit
  • Remove latch and latch spring

Step 12: Frame internals removal

Video: https://youtu.be/7hEL7NUBXSw?t=773

Cylinder alignment ball:

  • Remove screw
  • Remove spring
  • Remove ball

Firing pin removal (cylinder open): https://youtu.be/7hEL7NUBXSw?t=802

  • Drive out firing pin retaining pin (1/16 punch)
  • Drive firing pin out from the rear (9/64 punch)
  • Remove bushing

Mainspring removal: https://youtu.be/7hEL7NUBXSw?t=835

  • Remove mainspring retaining screw (5/64 bit)
  • Control mainspring guide with pliers
  • Remove guide and mainspring carefully

Step 13: Ultrasonic cleaning

Video: https://youtu.be/7hEL7NUBXSw?t=870

  • Clean frame and components
  • Dry thoroughly, especially holes and channels
  • Protect metal immediately with light lubrication

Reassembly overview

Follow the same system order:

  • Frame internals
  • Crane and cylinder
  • Trigger group
  • Hammer
  • Sights
  • Grip
  • Barrel, gap, shroud, nut
  • Final clean and function check

Step 14: Frame reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=912

Cylinder alignment ball:

  • Ball first
  • Larger spring next
  • Screw flush
  • Verify free movement

Firing pin installation: https://youtu.be/7hEL7NUBXSw?t=955

  • Install firing pin
  • Install spring
  • Install bushing with relief cut up
  • Install retaining pin

Mainspring installation: https://youtu.be/7hEL7NUBXSw?t=1006

  • Insert mainspring
  • Insert guide with hole side down
  • Compress and install retaining screw

Step 15: Crane and cylinder reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=1044

  • Install crane latch spring and latch
  • Install latch retaining screw
  • Install ejector rod bushing and spring in correct orientation
  • Install cylinder
  • Align extractor tabs and install extractor
  • Install ejector rod
  • Install bolt plunger and spring
  • Install bolt into frame
  • Install crane and crane lock

Step 16: Trigger group reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=1408

  • Install trigger return spring on guide
  • Seat guide correctly in trigger guard
  • Use punch to hold alignment, then replace with pivot pin
  • Install trigger assembly latch spring and latch
  • Install roll pin
  • Assemble hand, connector, and spring
  • Use a rubber band to hold parts during trigger guard install
  • Seat trigger guard and lock it with the latch

Step 17: Hammer installation

Video: https://youtu.be/7hEL7NUBXSw?t=1485

  • Assemble strut plunger and spring
  • Install into hammer
  • Install strut and pivot pin
  • Install hammer into frame while controlling trigger position
  • Install pivot pin
  • Release captured mainspring and return screw to frame

Step 18: Rear sight reassembly

Video: https://youtu.be/7hEL7NUBXSw?t=1529

  • Reinstall detent and spring
  • Install blade and retaining screw
  • Use grease to hold elevation springs in place
  • Pre-start roll pin, align holes, drive pin flush
  • Install elevation screw

You will re-zero at the range.

Step 19: Grip install

Video: https://youtu.be/7hEL7NUBXSw?t=1661

  • Slide grip onto tang
  • Install grip screw
  • Dry fire while tightening so you don’t bind the mainspring

Step 20: Barrel gap, shroud, and barrel nut

Video: https://youtu.be/7hEL7NUBXSw?t=1718

  • Install front sight on shroud
  • Thread barrel into frame most of the way
  • Set barrel-to-cylinder gap with a 0.006 feeler gauge
  • Install shroud onto frame pin with no gap at the frame
  • Install barrel nut carefully to avoid cross-threading
  • Snug barrel nut with the correct wrench

Step 21: Final cleaning and range prep

Video: https://youtu.be/7hEL7NUBXSw?t=1779

  • Brush bore
  • Patch until clean
  • Light oil pass through bore
  • Wipe exterior
  • Bore sight so you land on paper at the range

FAQ

What is the correct Dan Wesson barrel-to-cylinder gap?

This guide uses 0.006 inch with a feeler gauge during barrel setup. https://youtu.be/7hEL7NUBXSw?t=1718.

What if the barrel nut is damaged or rounded?

Use penetrating lubricant, soak time, and the correct barrel nut wrench. If the nut is compromised, replace it.

Do I have to use an ultrasonic cleaner?

No. It saves time and reaches tight areas. If you skip it, plan for more manual scrubbing.

Could a cylinder drag line be from someone spinning the cylinder?

Yes. A drag line can happen from normal operation. Aggressive spinning can make it worse. Check lockup and timing consistency.

What should I check after reassembly before live fire?

  • Cylinder opens and closes smoothly
  • Lockup feels consistent
  • Trigger resets correctly
  • Firing pin movement feels normal
  • Barrel gap is correct

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